U.S. patent number 11,207,945 [Application Number 16/465,075] was granted by the patent office on 2021-12-28 for flow control device, and control system and control method therefor.
This patent grant is currently assigned to Zhejiang Sanhua Intelligent Controls Co., Ltd.. The grantee listed for this patent is Zhejiang Sanhua Intelligent Controls Co., Ltd.. Invention is credited to Xuexia Gong, Huayuan Jiang, Zhi Wu, Yaoyao Zhang.
United States Patent |
11,207,945 |
Jiang , et al. |
December 28, 2021 |
Flow control device, and control system and control method
therefor
Abstract
A flow control device for use in a heat exchange system,
including: a housing, a movable valve member and a drive control
member, the housing being formed to have a mounting cavity, a first
interface and a second interface, while the drive control member
includes a control unit, a power output unit, a magnetic element
and a detection element; the power output unit provides power to
the movable valve member, while the detection element and the
control unit are electrically connected, and the magnetic element
and the power output unit are mutually assembled and oppositely
fixed, the power output unit may drive the magnetic element to
rotate; the detection element and the magnetic element are
oppositely disposed, the detection element being located within the
range of the magnetic field of the magnetic element, the detection
element may sense a magnetic pole change of the magnetic
element.
Inventors: |
Jiang; Huayuan (Zhejiang,
CN), Gong; Xuexia (Zhejiang, CN), Zhang;
Yaoyao (Zhejiang, CN), Wu; Zhi (Zhejiang,
CN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Zhejiang Sanhua Intelligent Controls Co., Ltd. |
Shaoxing |
N/A |
CN |
|
|
Assignee: |
Zhejiang Sanhua Intelligent
Controls Co., Ltd. (Shaoxing, CN)
|
Family
ID: |
1000006017829 |
Appl.
No.: |
16/465,075 |
Filed: |
November 29, 2017 |
PCT
Filed: |
November 29, 2017 |
PCT No.: |
PCT/CN2017/113452 |
371(c)(1),(2),(4) Date: |
May 29, 2019 |
PCT
Pub. No.: |
WO2018/099379 |
PCT
Pub. Date: |
June 07, 2018 |
Prior Publication Data
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|
|
|
Document
Identifier |
Publication Date |
|
US 20190283534 A1 |
Sep 19, 2019 |
|
Foreign Application Priority Data
|
|
|
|
|
Dec 1, 2016 [CN] |
|
|
201611087286.7 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F25B
41/20 (20210101); F16K 11/074 (20130101); G05D
7/0635 (20130101); F16K 31/042 (20130101); H02P
6/16 (20130101); F16K 11/24 (20130101); B60H
1/00814 (20130101); F16K 31/535 (20130101); G05D
7/06 (20130101); F16K 31/046 (20130101); B60H
1/00485 (20130101); F16K 37/0033 (20130101); G01D
5/2451 (20130101); H02P 29/024 (20130101); F01P
2007/146 (20130101) |
Current International
Class: |
B60H
1/00 (20060101); G05D 7/06 (20060101); F25B
41/20 (20210101); F16K 37/00 (20060101); F16K
31/04 (20060101); F16K 11/074 (20060101); F16K
31/53 (20060101); H02P 6/16 (20160101); F16K
11/24 (20060101); F01P 7/14 (20060101); H02P
29/024 (20160101); G01D 5/245 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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103782074 |
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May 2014 |
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CN |
|
204985849 |
|
Jan 2016 |
|
CN |
|
10 2006 026 537 |
|
Dec 2007 |
|
DE |
|
2 816 270 |
|
Dec 2014 |
|
EP |
|
3 502 531 |
|
Jun 2019 |
|
EP |
|
2 525 866 |
|
Nov 2015 |
|
GB |
|
H10-9416 |
|
Jan 1998 |
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JP |
|
2001-004052 |
|
Jan 2001 |
|
JP |
|
2003-329698 |
|
Nov 2003 |
|
JP |
|
WO 2014/072378 |
|
May 2014 |
|
WO |
|
Other References
Extended European Search Report for European Application No.
17876312.4, dated Jun. 24, 2020. cited by applicant .
International Search Report and Written Opinion for International
Application No. PCT/CN2017/113452, dated Feb. 24, 2018. cited by
applicant.
|
Primary Examiner: Cahill; Jessica
Assistant Examiner: Williams; Patrick C
Attorney, Agent or Firm: Wolf, Greenfield & Sacks,
P.C.
Claims
The invention claimed is:
1. A flow control device, comprising: a housing, a valve body
assembly and a drive control component, wherein the housing
comprises a first port and a second port; the valve body assembly
is partially received in the housing and comprises at least a
movable valve member and a transmission part, the movable valve
member is connected to the transmission part in a position-limited
manner, and the movable valve member is movably arranged relative
to the housing; and the drive control component comprises a control
unit, a power output unit, a magnetic element and a detection
element, wherein the power output unit is connected to the
transmission part in a position-limited manner, the power output
unit provides a driving force for the transmission part and the
movable valve member, the detection element is electrically
connected with the control unit, the magnetic element is assembled
with the power output unit and is fixed relative to the power
output unit, a sensing part of the detection element is located
within a magnetic field of the magnetic element and is arranged
opposite to an outer periphery of the magnetic element, and a
magnetic pole change generated by rotation of the magnetic element
is sensed by the detection element, wherein the magnetic element is
capable of performing circular motion when driven by the power
output unit, wherein the magnetic element comprises at least one
pair of magnetic poles, each pair of magnetic poles comprises an N
pole and an S pole which are distributed at an interval along the
circumferential direction of the power output unit, and the
magnetic poles sequentially pass through a sensing area of the
detection element when the magnetic element performs the circular
motion; the detection element is capable of interacting with the
magnetic poles of the magnetic element, to detect feedback signals;
and the control unit is provided with a set comparison upper limit
and is configured to compare the detected feedback signals with the
set comparison upper limit, determine whether the power output unit
operates normally, and control the power output unit to adjust.
2. The flow control device according to claim 1, wherein the power
output unit is configured to drive the transmission part to rotate,
and driven by the transmission part, the movable valve member is
capable of opening a flow channel between the first port and the
second port; the power output unit is configured to drive the
magnetic element to rotate, the detection element is spaced apart
from the outer periphery of the magnetic element by an induction
interval and obtains the feedback signals by sensing the magnetic
pole change of the magnetic element, and the control unit receives
the feedback signals and determines whether the power output unit
operates normally; and driven by the transmission part, the movable
valve member switches to an operation position of closing, and cuts
off the flow channel between the first port and the second
port.
3. The flow control device according to claim 2, wherein the
detection element is spaced apart from the magnetic element by the
induction interval, the drive control component comprises a printed
circuit board, the detection element and the control unit are
electrically connected with the printed circuit board, the flow
control device comprises a power component which drives the power
output unit to rotate, and the magnetic element rotates along with
the power output unit, the detection element senses the magnetic
pole change of the magnetic element; and the control unit obtains a
pulse signal corresponding to the magnetic pole change according to
the magnetic pole change detected by the detection element and
detects whether a pulse time width of the pulse signal is within a
normal operation range; or the detection elements senses the
magnetic pole change of the magnetic element to obtain a
periodically changing signal, and determines whether the movable
valve member of the flow control device is stalled by detecting
whether a period of the periodically changing signal is greater
than an upper limit of the normal operation range; and in a
direction perpendicular to a plane where the printed circuit board
is located, a projection of the sensing part on the printed circuit
board at least partially overlaps with a projection of the magnetic
element on the printed circuit board.
4. The flow control device according to claim 3, wherein the
printed circuit board comprises a main body base and an overhanging
portion, the detection element is assembled on one side of the
overhanging portion by welding and is disposed facing the magnetic
element, the printed circuit board comprises a first end and a
second end, the overhanging portion extends outward from the first
end and is overhung, the flow control device further comprises a
signal docking part, a signal terminal of the signal docking part
is electrically connected with the circuit board, and the signal
terminal of the signal docking part is assembled to the second end
by welding.
5. The flow control device according to claim 4, wherein the
detection element and the control unit are respectively secured to
the printed circuit board by welding, the printed circuit board
comprises a main body base and an overhanging portion, the
detection element is assembled on one side of the overhanging
portion by welding and is disposed facing the magnetic element, the
control unit of the drive control component is welded to the main
body base, the control unit and the detection element are arranged
on the same side or different sides of the circuit board, the
circuit board is provided with a printed circuit electrically
connected with the control unit and the detection element, and the
detection element is a Hall sensor.
6. The flow control device according to claim 2, wherein the flow
control device comprises a transmission system, the power output
unit is provided with a worm transmission part, and the worm
transmission part and a transmission input portion of the
transmission system form an engagement mechanism, and a
transmission output portion of the transmission system and the
movable valve member form a mechanical engagement mechanism; and
the worm transmission part and/or the magnetic element are/is
integrally formed with the power output unit; or the power output
unit is provided with a mounting portion which is assembled with
the magnetic element, the magnetic element is provided with a
mounting hole matching with the mounting portion, and the mounting
portion is partially located in the mounting hole.
7. The flow control device according to claim 6, wherein the power
component is a stepping motor, the power output unit drives the
magnetic element to rotate and drives the movable valve member via
the transmission system; when the movable valve member rotates by
one operation angle, the magnetic element generates one magnetic
pole change accordingly, and the detection element generates a
level signal; and the drive control component comprises a printed
circuit board, the detection element and the control unit are
electrically connected with the printed circuit board, the
detection element is a Hall sensor which comprises a main body and
weld legs, the main body of the Hall sensor is spaced apart from
the magnetic element by an induction interval less than 5 mm, the
weld legs are electrically connected with the printed circuit board
and are secured to the printed circuit board by welding, and a
position detection accuracy of the flow control device is equal to
or less than two degrees.
8. The flow control device according to claim 7, wherein the
magnetic element is configured to have a ring shape or a columnar
shape.
9. The flow control device according to claim 2, wherein the drive
control component comprises a printed circuit board, the detection
element and the control unit are secured to the printed circuit
board by welding, the printed circuit board comprises a main body
base and an overhanging portion, the detection element is assembled
on one side of the overhanging portion by welding and is disposed
facing the magnetic element, the control unit of the drive control
component is welded to the main body base, the control unit and the
detection element are arranged on the same side or different sides
of the circuit board, the circuit board is provided with a printed
circuit electrically connected with the control unit and the
detection element, and the detection element is a Hall sensor.
10. The flow control device according to claim 2, wherein the power
component is a stepping motor, the stepping motor comprises a motor
stator assembly and a motor output shaft, the motor output shaft
protrudes outward from a side of the motor stator assembly and
forms the power output unit, and the magnetic element is fixed
relative to the motor output shaft; and the drive control component
comprises a printed circuit board which comprises a main body base
and an overhanging portion, the overhanging portion protrudes from
an end of the main body base and extends along an extending
direction of the motor output shaft, the overhanging portion is
located on one side of the motor stator assembly along the radial
direction of the motor output shaft, the overhanging portion is
located on one side of the outer periphery of the magnetic element,
and the detection element is secured on a side of the overhanging
portion facing the magnetic element and is spaced apart from the
outer periphery of the magnetic element by the induction
interval.
11. The flow control device according to claim 2, wherein the drive
control component comprises a printed circuit board, the detection
element and the control unit are respectively secured to the
printed circuit board by welding, the flow control device further
comprises a motor assembly, which is provided with the power output
unit, the motor assembly further comprises a first grounding
element and a second grounding element, the first and second
grounding elements are assembled with each other, and the second
grounding element is electrically connected with the printed
circuit board by welding.
12. The flow control device according to claim 2, wherein the drive
control component comprises a printed circuit board, the detection
element and the control unit are secured to the printed circuit
board by welding, the printed circuit board comprises a main body
base and an overhanging portion, the detection element is assembled
on one side of the overhanging portion by welding and is disposed
facing the magnetic element, the housing comprises first
positioning protrusions and a second positioning protrusion, the
first positioning protrusions are located on both sides of the
overhanging portion, and the second positioning protrusion is
assembled with the main body base of the printed circuit board.
13. The flow control device according to claim 1, wherein the power
output unit drives the transmission part to rotate, and driven by
the transmission part, the movable valve member rotates, the power
output unit drives the magnetic element to rotate, the detection
element is spaced apart from the outer periphery of the magnetic
element by an induction interval and obtains the feedback signals
by sensing a magnetic pole change of the magnetic element, and the
control unit receives the feedback signals and determine whether
the power output unit operates normally; the detection element is
spaced apart from the magnetic element by the induction interval,
the drive control component comprises a printed circuit board, the
detection element and the control unit are electrically connected
with the printed circuit board, the flow control device comprises a
power component which drives the power output unit to rotate, and
the magnetic element rotates along with the power output unit; and
the detection element senses the magnetic pole change of the
magnetic element, the control unit obtains a pulse signal
corresponding to the magnetic pole change according to the magnetic
pole change detected by the detection element, and detects whether
the pulse time width of the pulse signal is within a normal
operation range; or the detection elements senses the magnetic pole
change of the magnetic element to obtain a periodically changing
signal, and it is determined whether the movable valve member of
the flow control device is stalled by detecting whether a period of
the periodically changing signal is greater than an upper limit of
the normal operation range.
14. The flow control device according to claim 1, wherein the power
output unit drives the magnetic element to rotate, the detection
element is spaced apart from the outer periphery of the magnetic
element by an induction interval, the detection element obtains the
feedback signals by sensing the magnetic pole change of the
magnetic element, the control unit receives the feedback signals
and determines whether the power output unit operates normally, and
driven by the transmission part, the movable valve member switches
to an operation position of closing and cuts off the flow channel
between the first port and the second port; and the flow control
device comprises a transmission system, the power output unit is
provided with a worm transmission part, the worm transmission part
and a transmission input portion of the transmission system form an
engagement mechanism, a transmission output portion of the
transmission system and the movable valve member form a mechanical
engagement mechanism; and the worm transmission part and/or the
magnetic element are/is integrally formed with the power output
unit; or, the power output unit is provided with a mounting portion
which is assembled with the magnetic element, the magnetic element
is provided with a mounting hole matching with the mounting
portion, and the mounting portion is partially located in the
mounting hole.
15. The flow control device according to claim 1, wherein the power
output unit drives the transmission part to rotate, and driven by
the transmission part, the movable valve member opens a flow
channel between the first port and the second port, the power
output unit drives the magnetic element to rotate, and the
detection element is spaced apart from the outer peripheral of the
magnetic element by an induction interval; the drive control
component comprises a printed circuit board, the detection element
and the control unit are secured to the printed circuit board by
welding, the printed circuit board comprises a main body base and
an overhanging portion, the detection element is assembled on one
side of the overhanging portion by welding and is disposed facing
the magnetic element, the control unit of the drive control unit is
secured to the main body base by welding, the control unit and the
detection element are arranged on the same side or different sides
of the circuit board, the printed circuit board is provided with a
printed circuit electrically connected with the control unit and
the detection element, and the detection element is a Hall sensor;
the flow control device comprises a power component, the power
component drives the power output unit to rotate, the magnetic
element rotates along with the power output unit, the detection
element senses the magnetic pole change of the magnetic element;
and the control unit obtains a pulse signal corresponding to the
magnetic pole change according to the magnetic pole change detected
by the detection element and detects whether the pulse time width
of the pulse signal is within a normal operation range; or, the
detection elements senses the magnetic pole change of the magnetic
element to obtain a periodically changing signal, and it is
determined whether the movable valve member of the flow control
device is stalled by detecting whether a period of the periodically
changing signal is greater than an upper limit of the normal
operation range.
16. The flow control device according to claim 1, wherein the power
output unit drives the magnetic element to rotate, the detection
element is spaced apart from the outer periphery of the magnetic
element by an induction interval, the detection element obtains the
feedback signals by sensing the magnetic pole change of the
magnetic element, the control unit receives the feedback signals
and determines whether the power output unit operates normally, and
driven by the transmission part, the movable valve member switches
to an operation position of closing and cuts off the flow channel
between the first port and the second port; and the drive control
component comprises a printed circuit board, the detection element
and the control unit are secured to the printed circuit board by
welding, the printed circuit board comprises a main body base and
an overhanging portion, the detection element is assembled on one
side of the overhanging portion by welding and is disposed facing
the magnetic element, the housing comprises first positioning
protrusions and a second positioning protrusion, the first
positioning protrusions are located on both sides of the
overhanging portion, and the second positioning protrusion is
assembled with the main body base of the printed circuit board.
17. A control method for the flow control device according to claim
1, wherein the power output unit of the flow control device is a
stepping motor; the control method comprising: operating the
stepping motor to drive the magnetic element to rotate; sensing, by
the detection element, the magnetic pole change of the magnetic
element and forming the feedback signals; collecting, by the
control unit, the feedback signals in a real-time manner and
obtaining the operation duration of the feedback signals; and
determining according to the operation duration of the collected
feedback signals, by the control unit, whether the stepping motor
is stalled, and sending out a stalling alarm signal if determining
that the stepping motor is stalled, and determining that the
stepping motor operates normally and continuing to perform one of
the above steps if determining that stepping motor is not stalled,
wherein the detection element senses the magnetic pole change of
the magnetic element and generates the feedback signals.
18. The control method for the flow control device according to
claim 17, further comprising: determining, by the control unit,
whether the operation duration of the feedback signals are greater
than 2 times of a set period T pre-stored in the control unit; and
determining, by the control unit, that a stalling occurs in the
flow control solution, and sending out, by the control unit, a
stalling alarm signal if determining that the operation duration of
the feedback signals are greater than 2 times of the set period T.
Description
This application is a National Phase entry of PCT Application No.
PCT/CN2017/113452, filed on Nov. 29, 2017, which claims priority to
Chinese Patent Application No. 201611087286.7, titled "FLOW CONTROL
DEVICE, AND CONTROL SYSTEM AND CONTROL METHOD THEREFOR", filed on
Dec. 1, 2016 with the State Intellectual Property Office of
People's Republic of China. The entire contents of these
applications are incorporated herein by reference in their
entireties.
FIELD
The present application relates to an electronically controlled
flow control device, and a control system and a control method
therefor.
BACKGROUND
The electric vehicle thermal management system includes a coolant
circulation system, which consists of a heat exchanger, a power
electronic, a drive motor, an on-board charger, a water-storage
kettle, an electric water pump, a reversing valve, a high
temperature area of a radiator tank, a high pressure PTC heating
device and an air conditioner radiator. A reversing device is
circularly connected through a pipeline and can be used for
switching the flow direction of the coolant. For instance, a hybrid
car is usually provided with the PTC heating device to make up for
the lack of residual heat of the engine. In this case, it may be
required to switch the coolant to the PTC heating device. In the
process of switching to the PTC heating device, a reversing valve
is also required to switch the flow direction of the coolant.
Currently, the coolant reversing device such as a motor-driven
piston valve is very widely applied in the hybrid and pure electric
vehicle industries. The piston valve is provided with a valve core
assembly in its valve body, and the valve core assembly is
connected with a gear decelerating mechanism through a valve core
shaft. When driven by the motor, the gear decelerating mechanism
drives the valve core assembly to perform reciprocating linear
movement to change a sealing position. However, a seal ring used in
the piston valve is made of rubber material, which is easily
over-deformed or damaged under the squeezing of the movable valve
core. Therefore, after a period of use, the movable valve core is
easily blocked to stop moving, which affects the normal operation
of the piston valve in the system.
SUMMARY
It is an object of the present application to provide a flow
control device which is capable of detecting the operation state in
a real-time manner.
To achieve the above object, the flow control device according to
the present application adopts the following technical solution. A
flow control device includes a housing, a valve body member and a
drive control component. The housing includes a first port and a
second port, and the valve body member is partially received in the
housing. The valve body member at least includes a movable valve
member and a transmission part, the movable valve member is
connected with the transmission part in a position-limited manner,
and the movable valve member is movably arranged relative to the
housing. The drive control component includes a control unit, a
power output unit, a magnetic element and a detection element,
where the power output unit is connected with the transmission part
in a position-limited manner, the power output unit provides a
driving force for the transmission part and the movable valve
member, and the detection element is electrically connected with
the control unit. The magnetic element is assembled with and is
fixed relative to the power output unit. A sensing part of the
detection element is located within the magnetic field of the
magnetic element and is disposed opposite to an outer periphery of
the magnetic element. The detection element is capable of sensing a
magnetic pole change generated by rotation of the magnetic
element.
The present application also discloses a control system for the
flow control device, which at least includes a magnetic element, a
detection element and a control unit. Driven by the power output
unit of the flow control device, the magnetic element is capable of
performing circular motion. The magnetic element includes at least
one pair of magnetic poles, each pair of magnetic poles includes an
N pole and an S pole, which are disposed at an interval along the
circumferential direction of the power output unit. When the
magnetic element performs circular motion, the magnetic poles
sequentially pass through a sensing area of the detection element.
The detection element can interact with the magnetic pole of the
magnetic element, to detect a feedback signal. The control unit is
provided with a set comparison upper limit, and is configured to
compare the detected feedback signal with the set comparison upper
limit, and determine whether the power output unit operates
normally, and control the power output unit to adjust.
The present application also discloses a control method for the
flow control device. The flow control device is provided with the
control unit, the power output unit, the magnetic element and the
detection element which cooperate to detect and/or control the flow
control device. The magnetic element is fixedly arranged relative
to the power output unit, and the magnetic element includes at
least two magnetic poles. The control method includes the following
steps: the stepping motor operating to drive the magnetic element
to rotate; the detection element sensing the magnetic pole change
of the magnetic element and forming a feedback signal; the control
unit collecting the feedback signal in a real-time manner and
obtaining the operation duration of the feedback signal; and the
control unit determining whether the stepping motor is stalled
according to the operation duration of each collected feedback
signal, sending out a stalling alarm signal if determining that the
stepping motor is stalled, and determining that the stepping motor
operates normally and continuing to perform one of the above steps
if determining that stepping motor is not stalled, where the
detection element senses the magnetic pole change of the magnetic
element and generates the feedback signal.
In the technical solution of the present application, the magnetic
element and the power output unit are mutually assembled and are
fixed relative to each other, and the power output unit drives the
magnetic element to rotate, and the detection element is disposed
opposite to the magnetic element. The sensing part of the detection
element is located within the magnetic field of the magnetic
element, and the sensing part and the outer periphery of the
magnetic element are oppositely disposed, and the detection element
is capable of sensing a magnetic pole change of the magnetic
element, so that the control unit can obtain the operation state of
the movable valve member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective assembly view of a flow control
device;
FIG. 2 is a partially sectional view of the flow control device
shown in FIG. 1;
FIG. 3 is a perspective assembly view of some components of the
flow control device shown in FIG. 1, and schematically shows the
assembly of a drive control component and a transmission
system;
FIG. 4 is a schematic perspective view of a valve body assembly, a
power output unit and a transmission system of the flow control
device shown in FIG. 1;
FIG. 5 is a perspective assembly view of some components of the
flow control device shown in FIG. 1 and schematically shows the
assembly of a drive control component and a transmission
system;
FIG. 6 is a partially sectional view of the flow control device
shown in FIG. 5 and schematically shows the relationship of the
drive control component;
FIG. 7 is a perspective assembly view of some components of the
flow control device shown in FIG. 5 and schematically shows the
assembly of the drive control component;
FIG. 8 is a schematic assembly view of the printed circuit board
and related electronic components shown in FIG. 3;
FIG. 9 is a schematic partially-enlarged view of the printed
circuit board and the detection element shown in FIG. 8;
FIG. 10 is a schematic view of the positional relationship between
the magnetic element and the detection element shown in FIG. 7, and
schematically shows the correspondence relation between the
rotation angle of a magnetic element and the rotation angle of a
movable valve plate;
FIG. 11 is a schematic view of a part of feedback signals provided
by a detection element of the flow control device to a control
unit; and
FIG. 12 is a flow chart of a control method for the flow control
device.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring to FIG. 1 and FIG. 2, a flow rate control device 100 may
be applied to a heat exchange system, for example, an automotive
air conditioning system or a domestic air conditioning system. A
flow medium of the flow rate control device may be water, a mixture
medium of water and other liquids, or a cooling medium having
heat-conduction capacity. The flow rate control device 100 is
configured to control distribution of the flow medium, and perform
heat exchange between the flow medium and other working medium of
the heat exchange system, and further to control a medium flow rate
of a flow path of the heat exchange system by regulating a flow
rate distributed to a medium outlet of the flow rate control
device, thereby improving and optimizing a control performance of
the flow path of the heat exchange system. Specifically, the flow
rate control device 100 can be applied to an air conditioner of the
new energy vehicle such as a heating ventilation air conditioner, a
battery cooling system or a battery heating system. The flow rate
control device 100 is configured to proportionally distribute the
working medium from an inlet to different outlets or switches the
working medium between different inlets and outlets through a
multi-way structure. The flow rate control device 100 may be
arranged in two or more heat exchange system circuits. The flow
rate control device 100 can switch a flow path in cooperation with
the heat exchange system, and can proportionally distribute flow
rates of different flow paths of the heat exchange system.
The flow control device 100 includes a housing 1, a valve body
assembly 2, and a drive control component 3. The valve body
assembly 2 is at least partially received in a mounting cavity of
the housing 1. The valve body assembly 2 includes a movable valve
member 21 and a transmission part 22. The movable valve member 21
is arranged movably relative to the housing. In this embodiment,
the valve body member 2 further includes a fixed valve member 23,
which is fixed and sealed relative to the housing, and the movable
valve member 21 is sealed relative to the fixed valve member 23.
Specifically, the movable valve member is a movable valve plate,
and the fixed valve member is a fixed valve plate or is formed by a
part of the housing. Herein, the terms "fixed" and "movable" are
both defined relative to the housing, and under the "fixed"
condition, slight shaking is also permitted. The housing 1 further
includes at least two ports. Specifically, the housing in this
embodiment includes three ports: a first port 102, a second port
103 and a third port 104. When driven by the transmission part, the
movable valve member 21 can open or close a flow channel between
the first port and the second port. One of the first port 102 and
the second port 103 is an inlet and the other is an outlet, thus
realizing a control mode of one input and one output. The housing
may also include three or more ports for realizing control modes of
one input and two outputs, two inputs and multiple outputs, and/or
two inputs and one input, three inputs and two outputs. The drive
control component 3 drives the transmission part 22, and the
transmission part 22 brings the movable valve member 21 to rotate.
During the rotation of the movable valve member, the communication
between adjacent ports can be achieved through a communication port
of the movable valve member 21. The flow rate of the port can also
be controlled by controlling a rotation angle of the movable valve
member, so that the flow rate control and reversing of the working
medium can be realized by rotating the movable valve member, thus
the flow control device 100 is multipurpose and thus can be
universally applied.
As shown in FIG. 3 to FIG. 8, the driving control member 3 includes
a power output unit 31, a magnetic element 32, a detection element
33, a control unit 34, and a printed circuit board 35. The power
output unit 31 is connected to the transmission part 22 in a
position-limited manner. The power output unit provides a driving
force for the transmission part and the movable valve member. The
detection element 33 and the control unit 34 are electrically
connected. The flow control device 100 includes a drive shell 30,
including a first shell and a second shell which can be connected
by welding to form a sealed configuration. The drive shell 30 forms
a mounting space 300, and the drive control component 3 is located
in the mounting space 300, which facilitates the drive control
component to protect against dust and water. The detection element
33 and the control unit 34 are electrically connected to the
printed circuit board 35 respectively. Specifically, the detection
element 33 and the control unit 34 are welded to the printed
circuit board 35 respectively. The magnetic element 32 is fitted
with the power output unit 31 and is fixed relative to the power
output unit 31. The power output unit can bring the magnetic
element to rotate. The detection element 33 is arranged opposite to
the magnetic element 32, and is located within a magnetic field
range of the magnetic element. The detection element can sense a
magnetic pole change caused by the rotation of the magnetic
element. Based on a feedback signal which is correspondingly
generated due to the magnetic pole change, such as a pulse signal
or other periodically changing signals, the control unit can obtain
the operation state of the movable valve member. The detection
element 33 obtains the feedback signal by sensing the magnetic pole
change of the magnetic element 32, the feedback signal corresponds
to a position change amount of the magnetic element, so that the
detection element 33 provides the detected signal to the control
unit. The control unit can receive the feedback signal and
determine whether the power output unit operates normally. The
printed circuit board 35 includes a main body base 351 and an
overhanging portion 352, where the overhanging portion protrudes
from one end of the main body base and is overhung. The housing 1
includes first positioning protrusions 11 and a second positioning
protrusion 12, where the first positioning protrusions are located
on both sides of the overhanging portion 352, and the second
positioning protrusion 12 is assembled with the main body base 351
of the printed circuit board. The detection element 33 is assembled
on one side of the overhanging portion 352 by welding, and is
disposed facing the magnetic element 32. The control unit 34 of the
drive control component is secured to the main body base portion
351 by welding. The control unit and the detection element are
arranged on the same side of the printed circuit board to
facilitate manufacture of the printed circuit board, or the control
unit and the detection element are arranged on different sides of
the printed circuit board, to relatively reduce the volume of the
printed circuit board assembly. The printed circuit board 35 is
provided with a printed circuit (not shown), where the printed
circuit is electrically connected with the control unit 34 and the
detection element 33. The flow control device further includes a
signal docking part 36, where a signal terminal 361 of the signal
docking part is electrically connected with the printed circuit
board 35. Specifically, the printed circuit board 35 includes a
first end 353 and a second end 354, the overhanging portion 352
extends outward from the first end and is overhung, and the signal
terminal of the signal docking part is welded to the second end
354, thereby establishing an electrical path for the electrical
signal transmission between the signal docking part and the printed
circuit board.
The flow control device includes a power component. In this
embodiment, a stepping motor 4 is used as the power component. The
stepping mother is located in the mounting space 300 of the drive
shell 30. The control unit 34 acquires an operation signal of the
stepping motor, and sends out different control signals to the
stepping motor according to the acquired operation signal of the
stepping motor, so that the control unit can control the stepping
motor. The power member provides power for the stepping motor and
the control unit. The control unit may be provided in the flow
control device; or the control unit may not be provided in the flow
control device but in a main control system to which the flow
control device is applied, and the flow control device is provided
with a driver that receives a control signal and converts the
control signal into a drive signal, which can also achieve the
control of the flow control device. The stepping motor includes a
motor stator assembly 40 and a motor output shaft, where the motor
output shaft protrudes outward from a side of the motor stator
assembly, and forms the power output unit 31. That is, the stepping
motor 4 provides the power output unit 31. Along the extending
direction of the output shaft, the overhanging portion 352 is
located on one side of the motor stator assembly 40, and along the
radial direction of the motor output shaft, the overhanging portion
352 is located on one side of the outer periphery of the magnetic
element. The detection element 33 is fixed on one side of the
overhanging portion toward the magnetic element 32, and further is
spaced at an induction interval from the outer periphery of the
magnetic element, so that the detection element can sense the
magnetic pole change of the magnetic element. A sensing part of the
detection element 33 is located within the magnetic field of the
magnetic element 32, and the sensing part is disposed opposite to
the outer periphery of the magnetic element. In a direction
perpendicular to a plane where the printed circuit board is
located, the projection of the sensing part on the printed circuit
board at least partially overlaps with the projection of the
magnetic element (specifically, a magnetic ring) on the printed
circuit board. Specifically, in the plane of the printed circuit
board, the projection of the extending direction of the motor
output shaft intersects with the extending direction of the
overhanging portion 352, or the projection of the extending
direction of the motor output shaft may also be parallel to the
extending direction of the overhanging portion 352, thereby meeting
the space layout requirements of the components in the shell of the
drive control component of the flow control device.
The flow control device further includes a motor assembly, which
includes a first grounding element 41 and a second grounding
element 42, where the first grounding element and the second
grounding element are mutually assembled and fixed, and the second
grounding element 42 is welded and electrically connected to the
printed circuit board 35. The stepping motor 4 further includes a
signal transmission terminal 43, and a tail end of the signal
transmission terminal is plugged into the mounting hole of the
printed circuit board, such that an electrical control signal can
be transmitted to the stepping motor.
As shown in FIG. 9 to FIG. 11, the power component (stepping motor)
drives the power output unit 31 to rotate, the magnetic element 32
rotates along with the power output unit, and the detection element
33 senses the magnetic pole change of the magnetic element 32 to
obtain a pulse signal, such that the control unit can obtain the
operation state of the movable valve member. By detecting whether a
pulse time width of the pulse signal is within the normal operation
range, specifically, by detecting whether the pulse time width is
greater than an upper limit of the normal operation range, or, by
detecting whether a period time width of the periodically changing
signal, which is obtained by the detection element 33 sensing the
magnetic pole change of the magnetic element, is within the normal
operation range, the control unit determines whether the movable
valve member of the flow control device is stalled.
The stepping motor 4 is provided with a power output unit, and the
magnetic element 32 is mounted on the power output unit. When the
stepping motor 4 operates, the power output unit 31 rotates, and
the magnetic element 32 rotates along with the power output unit
31. The detection element 33 interacts with the magnetic element
32. The detection element 33 is configured to sense the magnetic
field change of the magnetic element 32 and form a pulse signal.
The detection element can obtain the pulse signal. It can be
determined whether the movable valve member of the flow control
device is stalled by detecting the switching interval of the pulse
signal. The control unit 34 includes a microprocessor, which is
fixed relative to the printed circuit board 35. The microprocessor
is configured to collect a feedback signal and determine whether
the feedback signal is normal. The detection element 33 can be a
Hall sensor, a position sensor or other position detectors. The
feedback signal of the Hall sensor is a Hall signal, and the
feedback signal of the position sensor is also a Hall signal. The
magnetic element 32 includes at least one pair of magnetic poles.
Each pair of magnetic poles includes an N pole and an S pole, and
the N pole and the S pole are distributed at an interval along the
circumferential direction of the power output unit 31. When each
magnetic pole (N pole or S pole) of the magnetic element passes
through the Hall sensor, the magnetic pole interacts with the Hall
sensor to generate a level signal. High detection accuracy can be
realized by combining the Hall sensor and the magnetic pole. The
Hall sensor includes a main body 331 and weld legs 332, where the
main body 331 is a sensing part for detection, and the weld legs
332 are secured to the printed circuit board 35 and electrically
connected to the printed circuit board 35 by welding. Specifically,
the printed circuit board 35 is provided with a welding portion
3511 or connection guiding holes, and the welding legs 332 are
welded and electrically connected to the printed circuit board by
surface mounting technology (SMT), or the weld legs may also pass
through the connection guiding holes of the printed circuit board
and be welded and electrically connected to the printed circuit
board by passing-through-hole mounting.
In this embodiment, the flow control device is provided with a
stepping motor, and the magnetic element is a magnetic ring or a
columnar magnet. The magnetic element includes 2 N poles and 2 S
poles, and the power output unit 31 of the stepping motor is
configured as a rotation shaft, which may also be referred to as
the motor output shaft and extends outward from the housing of the
stepping motor. The magnetic element is assembled with the power
output unit, and includes four magnetic poles arranged along the
circumference of the power output unit. The Hall sensor is located
at the outer periphery of the magnetic element and is disposed
close to the magnetic element. When the magnetic element rotates
along with the power output unit of the motor, the N poles and the
S poles of the magnetic element alternately pass through the Hall
sensor, and the Hall sensor generates a periodic feedback signal.
The feedback signal is a square wave, once the magnetic pole of the
magnetic element passing through the Hall sensor changes from the N
pole to the S pole or from the S pole to the N pole, one feedback
signal is generated, that is, the feedback signal changes from a
low level signal to a high level signal or from a high level signal
to a low level signal. When the stepping motor completes one
revolution, that is, the magnetic element completes one revolution,
4 feedback signals are generated, and the duration of one magnetic
pole passing through the Hall sensor represents the operation
duration of the feedback signal. The control unit collects the
above feedback signal and determines the operation state of the
stepping motor based on the state of the feedback signal. The
operation state of the stepping motor at least includes a normal
operation state and a stalled state.
The flow control device includes a transmission system 44, and the
power output unit 31 includes a worm transmission part 311. The
worm transmission part 311 and/or the magnetic element 32 are/is
integrally formed with the power output unit 31. Alternatively, the
worm transmission part 311 and/or the magnetic element 32 are
coaxially sleeved on the outer periphery of the power output unit
31. The power output unit 31 further includes a mounting portion
312, which is assembled with the magnetic element 32, and the
magnetic element 32 is provided with a mounting hole 321 matching
with the mounting portion, and the mounting portion 312 passes
through the mounting hole. The worm transmission part 311 is
configured to have a cylindrical shape and is sleeved on the outer
periphery of the power output unit. The worm transmission part 311
forms an engagement mechanism with the transmission system 44. The
power output unit 31 drives the movable valve member via the
transmission system. When the movable valve member rotates by one
operation angle, one magnetic pole change of the magnetic element
32 occurs, and the detection element 33 correspondingly generates
one level signal, such that the control unit can obtain the
operating state of the movable valve member. Specifically, the
transmission system 44 is a gear transmission system which
transmits the driving force of the stepping motor to the movable
valve member 21. In this embodiment, the magnetic element is
configured as a magnetic ring or a columnar magnet, and the power
output unit of the stepping motor is provided with a mounting shaft
portion 313. The worm transmission part 311 forms an engagement
mechanism with the transmission system, where the mounting shaft
portion 313 is inserted into the mounting hole 321. The worm
transmission part 311 is assembled with the mounting shaft portion
313, or the worm transmission part 311 may also be integrally
formed with the mounting shaft portion 313.
When each magnetic pole of the magnetic ring 32 passes through the
Hall sensor, one level signal is generated. A position detection
accuracy s of the flow control device 100 is represented by a
rotation angle a of the movable valve member, which can be detected
by the Hall sensor, that is, the minimum rotation angle of the
movable valve member which can be detected by the Hall sensor.
There are two parameters influencing the position detection
accuracy s, i.e., a transmission ratio i of the transmission
system, and the number of poles M of the magnetic ring. The
position detection accuracy s can be expressed by the equation:
s=360/i/m. For instance, the transmission ratio i is 312, the
number of poles M of the magnetic ring is 2 to 10. Given that the
number of poles of the magnetic ring is constant, when the
transmission ratio i is decreased or increased, the position
detection accuracy s increases or decreases correspondingly.
Combining these parameters, the detection accuracy of the flow
control device is equal to or less than two degrees (2.degree.),
which can be further optimized to 1.degree., and is specifically
less than 0.57 degree and greater than 0.14 degree.
Taking a quadrupole magnetic ring as an example, the transmission
ratio i of the gear transmission system is 312, one level signal is
generated when each magnetic pole of the magnetic ring passes
through the Hall sensor. Then, once the stepping motor rotates by
one revolution (360.degree.), the movable valve member rotates by
360.degree./312=1.15.degree., and the Hall sensor generates four
level signals. When the machining precision of the gear
transmission system is approximately the same, the position
detection accuracy of the transmission output portion or the
movable valve member, which can be detected by the Hall sensor, is:
360.degree./4/312=0.29.degree., that is, when the number of poles
of the magnetic ring corresponding to the level signal, which is
generated by the Hall sensor, is 1 (90.degree.), the movable valve
member correspondingly rotates by 0.29.degree.. In other words, if
the movable valve member rotates by 0.29.degree., the Hall sensor
feeds one level signal back to the control unit of the printed
circuit board. That is, the position change of 0.29.degree. of the
movable valve member can be detected. Taking the six-pole magnetic
ring as an instance, the position detection accuracy of the
transmission output portion or the movable valve member which can
be detected by the Hall sensor is: 360.degree./6/312=0.19.degree..
Of course, in other embodiments, the number of poles of the
magnetic ring may also be 8 to 10. For instance, for an eight-pole
magnetic ring, the position detection accuracy of the Hall sensor
is 360.degree./8/312=0.14.degree.. If the number of poles of the
magnetic ring corresponding to each level signal is 1, the
correspondingly moving angle of the movable valve member controlled
is 0.14.degree. to 0.57.degree.. Therefore, if the movable valve
member moves by 0.14.degree. to 0.57.degree., the Hall sensor
generates one level signal correspondingly, so that the position
change of two degrees or less of the movable valve member can be
detected. By the interaction between the Hall sensor and the
magnetic ring arranged on the periphery of the output shaft of the
stepping motor, the position detection accuracy of the movable
valve member can be greatly improved.
The detection element 33 is spaced apart from the outer periphery
of the magnetic element 32 by an induction interval. Particularly,
the main body 331 of the detection element 33 is spaced apart from
the magnetic element 32 by an induction interval, which is less
than 5 mm. The main body of the sensor is located in an area
between the printed circuit board and the motor output shaft, which
can effectively utilize a spatial position between the components
and has little influence on the original structure, and thus is
favorable for saving costs. Specifically, in the radial direction
of the magnetic element, the outer periphery of the magnetic
element 32 is spaced apart from the top of the detection element 33
by a distance L, which is greater than or equal to 2 mm and less
than or equal to 3 mm. In this way, the overall height of the
printed circuit board and the motor output shaft can be reduced,
and the sensitivity of the detection element 33 can be
increased.
Specifically, referring to FIG. 10 to FIG. 12, when the flow
control solution works normally, the magnetic pole of the magnetic
ring corresponding to the sensor rotates from the N pole to a
junction between the N pole and the S pole during the operation of
the stepping motor, and the corresponding feedback signal is low
level. With the operation of the stepping motor, the magnetic pole
of the magnetic ring corresponding to the sensor changes from the N
pole to the S pole, and the feedback signal jumps to a high level
signal. With the stepping motor continuing to operate, the magnetic
pole of the magnetic ring corresponding to the sensor rotates from
the S pole to the junction between the N pole and the S pole, the
feedback signal is maintained at high level. With the operation of
the stepping motor, the magnetic pole of the magnetic ring
corresponding to the sensor changes from the S pole to the N pole,
the feedback signal jumps to a low level signal. The above
circulation is repeated. For each revolution of the magnetic ring,
4 feedback signals are generated, and the operation duration of
each feedback signal is set as a time width T of the normal
operation pulse. When a stalled situation occurs in the flow
control solution, the magnetic ring usually does not rotate, so the
feedback signal maintains a current state, and the duration t1 for
which the high level or the low level signal is maintained exceeds
a set normal pulse duration T. Double or other multiples of the set
normal pulse duration T may be defined as the set upper limit for
comparing with the operation pulse duration t1.
The present application further provides a control system for
controlling the flow control device. The control system at least
includes a magnetic element 32, a detection element 33 and a
control unit 34.
The magnetic element 32 is capable of performing circular motion
synchronously with the power output unit 31 of the flow control
device. The magnetic element includes at least one pair of magnetic
poles, where each pair of magnetic poles includes an N pole and an
S pole, the N pole and the S pole are distributed at an interval
along the circumferential direction of the power output unit 31.
When the magnetic element performs the circular motion, the
magnetic poles sequentially pass through the sensing area of the
detection element.
The detection element 33 can interact with the magnetic pole of the
magnetic element and detect a feedback signal. Specifically, the
feedback signal is high-low level signal, a pulse signal or other
periodically changing signal;
The control unit 34 is provided with a set comparison upper limit.
By comparing the detected feedback signal with the set comparison
upper limit, the control unit determines whether the power output
unit operates normally, and controls the power output unit to
adjust. When the movable valve member of the flow control is
stalled, the magnetic ring does not move, no pulse is generated,
and the level detected does not change, and at this time the
abnormality can be determined. Specifically, when the feedback
signal is the high-low level signal/the pulse signal or other
periodically changing signals, and the time width of the feedback
signal is greater than the comparison upper limit, it can be
determined that the movable valve member operates abnormally, such
as being stalled, and the power output unit 31 may be controlled to
adjust. For instance, the actual operation pulse time width t1
corresponding to the feedback signal detected by the Hall sensor is
greater than the double of the normal pulse duration T, and in this
case, it is determined that the operation state is abnormal and a
stalling occurs.
Referring to FIG. 12 again, the present application further
provides a control method for a control system. The control system
includes a stepping motor, a control unit, and a sensor, where a
power output unit of the stepping motor is provided with a magnetic
ring, which includes a plurality of magnetic poles, and
specifically includes at least two pairs of magnetic poles. The
control method includes the following steps S1 to S4.
In step S1, the stepping motor operates, and the magnetic ring
rotates (circular motion).
In step S2, the sensor senses the magnetic pole change of the
magnetic ring and generates a feedback signal.
In step S3, the control unit collects the feedback signal in a
real-time manner and obtains the operation duration of the feedback
signal.
In step S4, the control unit determines whether the stepping motor
is stalled according to the operation duration of each collected
feedback signal, and sends out a stalling alarm signal if the
stepping motor is stalled, and determines that the stepping motor
operates normally and the procedure goes to step S2 if the stepping
motor is not stalled. The above operation is repeated.
In the above step S4, a set period T is pre-stored in the control
unit, and the control unit determines whether the operation
duration of each feedback signal is greater than the double of the
set period. If the operation duration of each feedback signal is
greater than the double of the set period, it is determined that a
stalling occurs in the flow control solution, and the control unit
sends out a stalling alarm signal.
The flow control device 100 can be applied to the heating
ventilation air conditioning of a new energy automobile, and a
battery cooling or battery heating system, and specifically,
relates to the moving position detection and stalling detection of
the movable valve member of the flow control device, the detection
element employs the Hall sensor and the magnetic ring which
cooperate with each other. The detection element moves
synchronously with the power output unit of the motor, and is
easily installed and can effectively improve the position detection
accuracy. Further, with utilization of the change of the
transmission ratio of the transmission system, the position
detection accuracy of the movable valve member can be further
improved, such that the number of magnetic poles of the magnetic
ring can be reduced, the outer diameter of the magnetic ring can be
reduced, thereby reducing the volume of the magnetic ring.
It should be noted that the above embodiments are merely for
illustrating the present application, but not for limiting the
technical solutions described in the present application. Although
the present specification describes the present application in
detail with reference to the above embodiments, it should be
understood that those skilled in the art can still modify or
equivalently substitute the present application. All the technical
solutions and their improvements which do not depart from the
technical essence and scope of the present application, should fall
within the scope of the claims of the present application.
* * * * *